Light Weight Magnesium OxyChloride Composition and Construction Board

Abstract

A high performance, light weight construction board includes unique low solids Magnesium Oxychloride binder systems filled, Expanded Polymer Beads (EPB) blended with Expanded Perlite and/or with Coal Fuel Fly Ash. Weight reductions for such compositions by incorporating proteinaceous foaming agents into the binder matrix. The use of Calcium and other alkali earth chlorides mixed with magnesium chloride, or totally replacing magnesium chloride, provides unexpected improvements in binder strength. The use of a unique polymer scrim with felt construction provides improved compressive and directional strength properties while also providing superior board pull and shear properties.

1 . A light-weight, highly durable Magnesium OxyChloride-based composition comprising:
 a low weight binder system including:
 low temperature calcined and highly reactive Magnesium Oxide; 
 at least one of: Magnesium Chloride, Calcium Chloride, or another alkali earth chloride; 
 water; 
 at least one of an aeration or foaming agent; and 
   a filler blend including Expanded Polymer Beads with at least one of Expanded Perlite and/or Fly Ash.   
     
     
         2 . The composition according to  claim 1 , wherein the low weight binder comprises from about 20% to about 80% based on the total weight of the composition. 
     
     
         3 . The composition of  claim 1 , wherein the binder system includes molar ratios of Magnesium Oxide:Alkali Earth Chloride:Water ranging from 5:1:13 to 7:1:17. 
     
     
         4 . The composition according to  claim 1  wherein the Magnesium Oxide comprises light calcined materials at varying temperatures ranging from 750 degrees F. to 1,700 degrees F. 
     
     
         5 . The composition according to  claim 2  wherein the Magnesium Oxide is acid treated with an acid. 
     
     
         6 . The composition according to  claim 1  wherein the Alkali Earth Chloride an Alkali Earth Mineral chloride. 
     
     
         7 . The composition according to  claim 1 , wherein the at least one of an aeration or foaming agents comprises an aqueous concentrate of a surface active polypeptide-alkylene polyol condensate and stabilized using hydroxyethyl or hydroxypropyl cellulose. 
     
     
         8 . The composition according to  claim 1  wherein the filler comprises at least one of: a blend including at least one of Expanded Polymer Beads (EPB) blended with Expanded Perlite, EPB blended with Fly Ash or EPB blended with Expanded Perlite; and Fly Ash. 
     
     
         9 . The composition according to  claim 8 , wherein the Expanded Polymer Beads comprise at least one polymer selected from the group consisting of: homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride; polyolefins; polycarbonates; polyesters; polystyrene, polyamides; natural rubbers; synthetic rubbers. 
     
     
         10 . A Magnesium OxyChloride-based construction board having an upper face and a lower face, comprising:
 a low weight binder system including:
 low temperature calcined and highly reactive Magnesium Oxide; 
 at least one of: Magnesium Chloride, Calcium Chloride, or another alkali earth chloride; 
 water; 
 at least one of an aeration or foaming agent; 
   a filler blend including Expanded Polymer Beads with at least one of Expanded Perlite or Fly Ash; and   a scrim fabric comprising reinforcing fabrics including synthetic fibers and a felt layer positioned over the upper and the lower faces.   
     
     
         11 . The composition of  claim 4 , wherein the Magnesium Oxide has a purity of at least 91% Magnesium Oxide. 
     
     
         12 . The composition of  claim 6 , wherein 1 wherein the Alkali Earth Mineral chloride comprises at least one of: Magnesium Chloride, Calcium Chloride, Potassium Chloride, Lithium Chloride. 
     
     
         13 . Magnesium OxyChloride-based construction board according to  claim 10 , wherein the scrim comprises at least one of fiberglass fibers, polyester fibers, natural fibers, or high modulus yarns.